Apparatus and process for forming tubular bodies

ABSTRACT

An apparatus and process for the automatic fabrication of tubular bodies from an inner core and a blank of outer wrap material to envelop the core which is stationarily secured within the wrap and bounded by a pair of end caps. The process and the apparatus for carrying out the process includes cutting means for dimensioning the blank, flanging means for forming opposed side flanges on the blank, wrapper seamer means for wrapping with the blank a properly oriented inner core and seaming the flanged sides, second flanging means for flanging the ends of the tubular body and end cap mounting means and seamer means all of which operate in an automatic production line.

United States Patent Small 1 Mar.7, 1972 [54] APPARATUS AND PROCESS FOR FORMING TUBULAR BODIES 21 Appl. No.: 848,512

[52] US. Cl ..29/200, 29/157, 113/1 [51] Int. Cl. ..B23p 19/00, B21d 53/00 [58] field of Search ..29/200 R, 200 A, 200 B, 200 D,

29/200 J, 200 P, 200, 208, 430, 211, 431, 234, 473.9, 235, 474.1, 157, 460; 113/1, 54, 1 E, l G

2,805,635 9/1957 Hale ..1 13/1 3,248,791 5/1966 Powers .....29/460 3,465,568 9/1969 Jonason.. 29/ 157.3 3,545,062 12/1970 Cox Primary Examiner-Harrison L. l-linson Attorney-Charles B. Cannon [57] ABSTRACT An apparatus and process for the automatic fabrication of tubular bodies from an inner core and a blank of outer wrap material to envelop the core which is stationarily secured within the wrap and bounded by a pair of end caps. The process and the apparatus for carrying out the process includes cutting means for dimensioning the blank, flanging means for forming opposed side flanges on the blank, wrapper seamer means for wrapping with the blank a properly oriented inner core and seaming the flanged sides, second flanging means for flanging the ends of the tubular body and end cap mounting means and seamer means all of which operate in an automatic production line.

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SHEET 160! 17 BERNARD J SMALL APPARATUS AND PROCESS FOR FORMING TUBULAR BODIES The present invention relates to both an apparatus and process for the formation of enclosed bodies. More particularly the present invention relates to an apparatus and process for the continuous automatic fabrication of automotive mufflers from an inner core and a blank of wrap material which envelops the inner core which is stationarily secured within the wrap and bounded by a pair of end caps.

Heretofore the formation of automotive mufilers has been carried out on basically what might be considered a manual operation or a series of sequential manual operations during which the mufflers were assembled, seamed, and capped at a number of different operating stations by a number of machine operators.

While the muffler manufactured in this manner. suffers in no way from an operational standpoint the thrust throughout not only the muffler industry but throughout most present day industries is toward greater or total mechanization. In this manner quality may be enhanced output may be increased to meet market demands. 7

However, although the thrust has been toward mechanization no system of muffler fabrication has, as yet, received acceptance throughout the industry.

The present invention, therefore, contemplates the provision of an assembly line system for the complete assembly of an automotive muffler during which and wherein the individual component parts are automatically assembled and formed together into a complete muffler.

One aspect of the invention contemplates an assembly system that broadly includes means to feed from coiled sheet stock a length of material for use as an outer wrap in the fabrication process. From the stock a predetermined length of material defining a section of material is cut upon demand of the system. Prior to cutting the sheet is cause to pass along a conveyor which functions to straighten or at least substantially relieves the tendency in the stock to bow and return to its previous coiled condition.

The section once cut and embossed as desired, is transported into a flanger unit within which a flange is applied along the full length of the uncut sides. The section to be flanged may, immediately prior thereto, have been cut from the stock or the section may be from stock and introduced to the system immediately prior to the stage. Irrespective of the source the feed of the section is automatically responsive to system demand.

The double flanged section is transported to the first assembly station. At a feed table for the assembly station, or the wrapper-seamer, a layer of asbestos, cut to proper size from a supply, is automatically or otherwise located on the section between the flanges. The asbestos provides a lining between the outer wrap and the oval inner muffler core later to be received at the feed table for movement with thelined section for assembly.

A second conveyor system driven in synchronism with the conveyed flanged sections is responsive to the presence of a lined sheet at the table entrance to a seamer and wrapper apparatus thereby to provide and orient a generally oval inner core in relation to the lined flanged section. The inner core is suitably separately supported above the lined flanged section after movement into the wrapper-seamer assembly so that upon movement of a ram the inner core may be wrapped. After wrapping, a seam is fon'ned along the length of the muffler by the sequential movement of a plurality of knives which act on the side flanges thereby to form a lock seam.

The present invention contemplates that the seam may be formed to be parallel either axis of the core. Therefore, the inner core is suitably oriented for movement into the seamer with this thought in mind. In the present embodiment to be discussed in detail, however, the seam is to be formed adjacent the end of the major axis. However, if the inner core is circular or in some other accepted configuration other considerations are required.

The seam is formed by sequential movement of a plurality of knives located adjacent the flanges. These knives function to create, with proper flange movement, a lock seam that secures the inner core and forms with the outer wrap a tubular body.

The seamed unit is conveyed by an accumulator to a further stage of the system wherein a short lateral flange or bead is formed at both open ends of the tubular body. These flanges adapt the body for receipt of a pair of end caps thereby to form a completed unit.

A second accumulator, which func,ions in a fashion similar to the first accumulator, receives the end-flanged unit for transport to the cap assembly station. The endcaps may be automatically fed from a pair of spaced magazines and frictionally received over the flange or bead to seal the interior core. As the inner core is provided with passages for communication with both the exhaust and tailpipes care is exercised to properly align the end caps on the tubular body. In this manner the exhaust and tailpipe may be properly mounted.

Final seaming of the end caps to the outer wrap completes the process to be discussed in'greater detailhereinafter.

The invention also contemplates the provision of a novel accumulator conveyor which transports, upon controlled need of the system, mufflers in stages of completion between various assembly. and operative. stations of the overall system. The conveyor allows for the accumulation between stations of the partially completed mufflers to allow for an increase in the rate. of production of the overall system to approximately 360 mufflers per hour. In this connection the conveyor path is significantly lengthened from the otherwise straight path between stations. Additionally, stock inventory may be introduced to the conveyor for delivery to following stations during periods of partial shutdown. Further still, the conveyor includes means whereby the seamed muffler, introduced to the conveyor in one position, may be reoriented during transit to a second position thereby to be properly aligned for further processing.

The invention also contemplates as a further aspect a novel end flanger for flanging simultaneously the opposite ends of the tubular body. In this connection the end flanger forms around the entire periphery of the tubular body a flange so that the body may frictionallyreceive a pair of end caps to enclose the inner core.

In view of the-foregoing brief consideration and the following more detailed discussion it will be apparent that the system is adaptable to varied needs and considerations and functions in a manner so as to carry out the objects and provide the benefits and advantages attributable thereto.

In carrying out the several objects the invention contemplates a method for automatically fabricating an automotive muffler comprising providing a blank of sheet material having predetermined dimensional characteristics, transporting said blank through the system in which opposed longitudinal sides of the blank are seamed after enwrapping as hereinafter defined inner core toform an open ended tubular member, transporting an inner core in synchronism with said transported blank and orienting said inner. core with respect to said blank at said station to enable it to be wrapped, applying end capping elements to said tubular member for enclosing said inner core, and sealing said elements to said member.

The objects are further carried out by a system for the automatic fabrication of automotive mufflers, the combination comprising a blank of sheet materialhaving predetermined dimensional characteristics; motive means for transporting said blank through said system including a wrapper and seamer unit for wrapping said blank around an hereinafter defined inner core and seaming the joined longitudinal edges of said blank to enclose said inner core and form a-tubular member, a flanger unit for forming a flange around the periphery at the open ends of the member for receipt of a pair of end caps, and a seamer unit for securing said end caps at said open ends to enclosed said inner core; and second motive means responsive to movement of. said first motive means for transporting said inner core in synchronism with the movement of said blank thereby to orient the inner core in relation to said blank to travel in consort therewith whereby said inner core is enwrapped in said blank and secured by said end caps within the aforementioned units.

Additional objects are carried out by the provision of an apparatus for use in a fabricating system comprising an endless conveyor connecting stages of the system and for conveying partially fabricated articles between said stages throughout an elongated passage which is greater than the distance between said stages, means for driving said conveyor in response to system demands and in synchronism to movement of said partially completed article through said system, means carried by said conveyor for supporting an article throughout movement in the elongated passage between an article inlet and an article outlet, said support means being mounted by the conveyor in a manner such that upon movement of the conveyor said support means is positioned to receive said article from an immediately preceding stage, means in said conveyor path for reorienting the received article from a n inlet position to a second position, and outlet means for passing said reoriented article to a following stage of said system.

There have thus been outlined rather broadly the more important features of the invention in order that the detailed description thereof that follows may be better understood and in order that the present contribution to the art may be better appreciated. There are, of course, additional features of the invention that will be described hereinafter and which will form the subject of the claims appended hereto. Those skilled in the art will appreciate that the conception upon which this disclosure is based may readily be utilized as a basis for the designing of other structures for carrying out the several aspects of the invention. It is important, therefore, that the claims be regarded as including such equivalent constructions as do not depart from the spirit and scope of the invention.

A specific application of the invention has been chosen for purpose of illustration and description, and is shown in the accompanying drawings forming a part of the specification, wherein:

FIG. 1 is a schematic block diagram of the operational stages included in the fabrication process;

FIG. 1A is a schematic block diagram of the operational stages of a modified fabrication process;

FIG. 2 is a side elevation of a portion of the system of FIG. 1;

FIG. 3 is a side elevation of an additional portion of the system of FIG. 1;

FIG. 4 is a top plan view of the structure as shown in FIGS. 2 and 3;

FIG. 5 is a side elevation of an additional portion of the system of FIG. 1;

FIG. 5A is a view similar to FIG. 5 yet viewing the system from the opposite side;

FIG. 6 is a side elevation of a further position of the system of FIG. 1;

FIG. 6A is a view similar to FIG. 6 showing a portion of the structure from the opposite side;

FIG. 7 is a top plan view of the apparatus of FIG. 5;

FIG. 7A is a view similar to FIG. 7;

FIG. 8 is a top plan view of the apparatus of FIG. 6;

FIG. 8A is a view similar to FIG. 8;

FIG. 9 is a side elevation of the terminal apparatus of FIG. 6 from the opposite direction;

FIG. 10 is a partial side view of a portion of the structure of FIG. 9;

FIG. 11 is a top plan view of the structure of FIG. 10;

FIG. 12 is a vertical section as seen along the line 12-l2 in FIG. 10;

FIG. 13 is a side elevation of the accumulator conveyor;

FIG. 14 is a vertical section as seen along the line 14-14 in FIG. 13;

FIG. I5 is a vertical section as seen along the line 15-15 in FIG. I4;

FIG. 16 is an enlarged view of the drive means for the accumulator conveyor;

FIG. 17 is a front elevation of the drive means as seen along the line 17-17 in FIG. I6;

FIG. 18 is a side elevation of the inner core member conveyor;

FIG. 19 is a top plan view of the conveyor of FIG. 18;

FIG. 20 is a front elevation of the conveyor of FIG. 18;

FIGS. 21 and 22 are views in cross section showing sequentially the rollers for folding the scam in the outer wrapping;

FIG. 23 is a side elevation of a sheet transport table;

FIG. 24 is a top plan view of the transport table of FIG. 23;

FIG. 25 is a vertical section as seen along the line 2525 in FIG. 23;

FIG. 26 is a side elevation of the hump table; and

FIG. 27 is a front elevation of the table as seen in the direction of the line 27-27 in FIG. 26.

The system and the processing stations for the fabrication of an automotive muffler may be seen in FIG. 1. The system generally includes a number of stations including operative apparatus and interconnecting conveyor means which, upon demand, delivers the structural components of the muffler for assembly.

The system includes a reeling apparatus 10 providing a coiled length of stock sheet material 12. The stock sheet material is unrolled from a reeling spindle 14 upon demand of the feeder 16 which, as later discussed, is primarily controlled by the wrapper-seamer unit. While not shown in the figure, the feeder includes a plurality of support rollers between spaced pairs of input and output rollers that are driven by a variable speed motor for fast start and stop motion. The feeder may develop a 15,000 lb. capacity in the uncoiling and feeding operation.

The sheet material is suitably of a width as detennined by the size of the muffler to be formed and may be stock of any gauge. For the sake of discussion the sheet material may be l4-gauge and it may be, because of the implementation of nylon coated rollers, used at various stages, either plated or prepainted prior to introduction into the system to be described.

While not shown in the figures the sheet material may be supported during its travel from the uncoiler 10 to the feeder 7 The feeder, in addition to drawing the sheet stock from the coiled roll, moves the stock toward a press 18 having once passed over a hump table" 100. The table, discussed in greater detail hereinafter, provides an arcuate path of travel for the sheet thereby to introduce a reverse bend to aid in overcoming the tendency of the sheet to bow as a result of the previous coiled disposition.

The feed 16 provides drive for the sheet material toward the press 18. The press accurately notches and cuts the sheet material into elongated sections 19 of, for example, 10' to 32" in length. Sections of a length between these limits may be fabricated into mufflers, the sections sewing as an outer wrap for a core that is delivered at a later stage. However, the system will, with adjustment, accept sections of greater length, for example, 40".

The press may be a positive pulldown press providing exact shear. Such a press, identified as an SP Moon Press," manufactured and sold by Moon Brothers, Ltd. Birkenhead, England, may suitably be employed for this operation.

As desired, the individual cut sections may also be embossed with manufacturer's indicia during the cutting or in a subsequent operation.

The cut sections 19 exit the press onto a transport table 20 mounting a constantly driven conveyor including an endless belt and a plurality of supporting spindles, all generally represented by the numeral 22 (FIG. 2). A pivot arm 24 is also carried by the table and in response to system demands functions to swing the sheet sections through an angle of for entry into the following station in the system. The sheets are driven by the conveyor square to the arm to proper alignment. The am is magnetic and hooks the section for movement. 

1. In a system for the automatic fabrication of automotive mufflers from a blank of sheet material having predetermined dimensional characteristics, the combination comprising motive means for transporting said blank through said system including a wrapper and seamer unit for wrapping said blank around an hereinafter defined inner core and seaming the joined longitudinal edges of said blank to enclose said inner core forming a tubular member, a flanger unit for forming a flange around the periphery at the open ends of the member for receipt of a pair of end caps, and a seamer unit for securing said end caps at said open ends to enclosed said inner core; and second motive means responsive to movement of said first motive means for transporting said inner core in synchronism with the movement of said blank thereby to orient said inner core in relation to said blank to travel in consort therewith whereby said inner core in enwrapped in said blank and secured by said end caps within the aforementioned units.
 2. The system of claim 1 further including reeling apparatus for carrying a coiled reel of sheet material, means for feeding said material and cutting means for cUtting said blank of predetermined dimension characteristics from said sheet.
 3. The system of claim 1 further including flanger means for forming longitudinal flanges along opposed sides of said blank prior to transporting said blank to said wrapper and seamer unit.
 4. The system of claim 1 wherein said second motive means includes conveyor means including a first path for moving said inner cores disposed in an upstanding position, a second path, means between said first and second paths for supporting said upstanding inner cores and for moving said inner cores onto said second path, and means within said second path for moving said core to a third path.
 5. The system of claim 1 wherein said wrapper and seamer unit includes a ram movable generally along the axis of said unit, means to move and stationarily dispose said inner core into said path of movement, means to move said blank into said path of movement and between the inner core and said ram whereby movement of said ram wraps said blank partially around said inner core.
 6. The system of claim 5 including a plurality of sequentially operable members, said members disposed adjacent the unwrapped portion of said inner core and operable to fully enwrap said core and form a longitudinal seam.
 7. The system of claim 6 including means to bend said seam onto said enclosing wrap.
 8. The system of claim 1 wherein said first motive means includes a conveyor connecting said wrapper and seamer unit and said flanger unit, and means for increasing the path of travel of said tubular member between said units.
 9. The system of claim 8 comprising means for reorienting the disposition of said tubular member during transit along said increased path, said means including an element mounted to project into said conveyor path thereby to cause said tubular member to pivot about said element end.
 10. The system of claim 1 wherein said flanger unit comprises a housing, a pair of elements supported for reciprocable movement within the housing along a common axis, means for supporting said tubular member within said housing in a manner such that its longitudinal axis is substantially coincident with said common axis thereby to be in position for receiving said peripheral flange, means to move said tubular body into said housing and into said position, and means for moving said movable elements against said tubular body to form said flange.
 11. In a system for the automatic fabrication of a tubular member from a blank of sheet material having predetermined dimensional characteristics for providing an outer wrap, the combination comprising motive means for transporting said blank through said system including a wrapper and seamer unit for wrapping said blank around an hereinafter defined inner element and seaming the joined longitudinal edges of said blank to enclose said inner element thereby forming a tubular member, a flanger unit for forming a flange around the periphery at the open ends of the tubular member for receipt of a pair of end caps, and a seamer unit for securing said end caps at said open ends to enclose said inner element; and second motive means responsive to movement of said first motive means for transporting said inner element in synchronism with the movement of said blank thereby to orient said inner element in relation to said blank to travel in consort therewith whereby said inner element is enwrapped in said blank and secured by said end caps within the aforementioned units. 